When it comes to innovating in

the nuclear industry, OPG's X-Lab
is at the forefront. This talented
team is dedicated to improving
and revolutionizing the tools,
systems and processes that
power Ontario. Their focus is on
driving improvements in safety,
reliability and efficiency, and
creating cost savings through
creative thinking.


  
   

IRI’s drive for innovation is part of

a strong commitment to deliver
top-of-the-line inspection and
maintenance services for critical
assets in the energy and nuclear
industries. Innovations in IRI
bring about the latest
developments in inspection
technologies, with the principle
goals of improving safety,   
 

z
reducing cost, and decreasing
personnel dose. Innovations at IRI

   

will go on to help clean energy
power Ontario for the years to  

come.   
ĝâ ⬝ â†Ä ¯Ù¯ ¼

 
 
 
   







 


 



 

   


  
   
 
 8*3&-&44 4."35 5&$)
OPG continues to improve its work practises by making everyone’s jobs
safer and more effective. X-Lab is committed to working collaboratively
with all part of the organization to enable technologies that will accelerate
such improvements. A line of Wireless Smart Tech products has been
developed that helps address many of the existing challenges we face in
the nuclear industry.

Imagine having a team of highly skilled mechanics constantly monitoring

your car. They tell you exactly when to change the oil and replace the
spark plugs. One of them even rides in the car with you and tells you to
watch out for pot holes, black ice or other drivers. Now imagine the
maintenance savings – you'd never get service you don't need, and you'd
always be ahead of problems before they happen. The goal of Smart
Wireless Tech is to achieve what we can only imagine.




 #BNT
Battery Monitoring System (BaMS) is a patented, custom-made Printed
Circuit Board designed by X-Lab to wirelessly monitor the status of
essential battery banks. BaMS can wirelessly report various battery
parameters such as individual cell voltage, current, temperature, capacity
and internal resistance.

Our plan is to deploy BaMS on every single battery bank across OPG,
enabling real-time, non-intrusive monitoring on the health of batteries.
This will improve reliability, safety, and drive efficiency throughout the
organization.

   
 
 


    
      

       



   
 5"-,*/( 3&-":4
X-Lab's Relay monitoring device increases productivity and eliminates risk
by enabling the user to wirelessly monitor the status of a relay without
connecting external monitoring equipment. For this application, the relay
‘talks' to a phone application or the Plant Information system, and is used
for status reporting and troubleshooting.

Interaction with this relay is through a pluggable hardware, which mounts

directly onto the octal connector of the relay. The simple connection is
attractive to operators and maintainers due to its ease of installation.

  
           
        
 3"% (-"44&4
This innovation allows the user to view their dose rate and accumulated
dose on Google Glass, which is connected to a personal dosimeter. This
will greatly reduce the time spent working in high radiation areas. This is
revolutionizing how we perform radiation work by greatly improving
worker safety and creating efficiency in both low and high-risk radiation
jobs.

The unit can also be used during high-risk work evolutions, such as work
on the reactor face. The wearer is able to communicate with a central
work authority or specialized point of contact during the work evolution.
This contact would be able to see exactly what the wearer is seeing and
direct work accordingly.

      
 
        
 
 

         

        
 
*/%003 53"$,*/(

"11-*$"5*0/

The indoor tracking application maps measured dose rates in X,Y,Z co-
ordinates, creating a radiation heat map as more data is collected. The=
heat map is then displayed to users before entering areas, reducing their=
risk of walking into highly radiated areas.

Additionally, automating the collection of surveys done by radiation=

technicians will prevent technicians from gaining unnecessary radiation=
dose. Changing the way we look at radiation work is an important step in=
the nuclear industry to help prevent dose and improve worker safety.
X-Lab's wireless asset tracking system allows assets to be tracked by
sticking a low profile plastic sealed enclosure to the asset's body. Not only
can these assets be tracked, but we can use them to keep a full
maintenance record inside the device.

The device location and maintenance record can be retrieved using

Android services over a phone or tablet in the field. Technology also allows
set up of geo-fencing. Users will be able to generate alerts when assets are
moved into or from designated areas.
   
OPG has brought Artificial Intelligence (AI) to our stations through the
establishment of the Monitoring & Diagnostic (M&D) Centre. X-Lab is
working to help expand the monitoring capabilities of the centre.

We're developing a suite of wireless sensors that are non-intrusive and can
be easily deployed in the field. Sensors that monitor for voltage, current,
capacity, vibrations, temperature, pressure, and sound will be deployed to
modernize our existing fleet of generating plants and help improve our
equipment reliability and maintenance practices.




    
 
 
Guided Wave Ultrasonic Testing (UT) is a technology which sends
ultrasonic waves down the length of a pipe. By leaving a Guided Wave
collar on the pipe it’s possible to monitor the pipe continuously for
degradation.

This online examination allows for inspections to be more targeted and

preventative repairs to be made. In addition, such testing can act as a
screening tool to point out problem areas prior to more detailed
examination. This eliminates the need to perform time-consuming high
precision ultrasonic techniques on the entire length of the pipe.

The end result is improved testing, increased component lifetime through

monitoring, and shorter and simpler inspection campaigns. These benefits
warranted proof of concept demonstrations at several facilities in OPG.
Most recently, a 60” collar was deployed at Darlington Nuclear.




   
 
   
Full Matrix Capture (FMC), is an advanced form of UT. The method collects
and processes data from arrays of ultrasonic probes. By capturing all
combinations of transmit-receive data, more accurate and representative
images of flaws and defects can be generated. Matrix Inspection
Technology is a version of FMC that has been patented by OPG in a
number of jurisdictions around the globe.

The goal is to modernize the current Fuel Channel inspection systems

(ANDE & CIGAR UT) to improve inspection resolution, productivity and
increase equipment reliability. Rotary motion in both systems leads to
challenges with multiple scans required to characterize a fuel channel. By
acquiring all UT scans simultaneously, no added scans or re-scans would
be required, and thus channel speeds on critical path would be greatly
reduced.




  
 


Lasers offer higher accuracy possibilities for the measurement of pressure
tube creep, with the Laser AXial Elongation (AXE) tool serving as a
promising technology entering the prototype testing phase. Using a single
mount in the vault, the scanner can determine the position of the tube
sheet and measure the relative positions of end fittings.

Pressure tube creep is a life-limiting aging occurrence for CANDU reactors,

and excessive creep must be monitored to determine the need for
intervention or possible single channel fuel replacement. Currently,
mechanical measurements are taken using devices mounted to fuelling
machines, taking considerable time with errors on the order of ±1mm.

The benefits of this tooling allows for substantial reductions in personnel

dose and critical path time associated with these measurements. The sub-
millimeter accuracy improves upon the current methods which in turn can
allow for more confident engineering decisions. Every second of critical
path time has a cost, and every second saved has value.



  
 

X-Lab is working to bring AI to our stations to help improve safety for all
OPG employees. Through collaboration with our vendor partners we are
working on deploying video recognition AI algorithms to monitor for
Personal Protective Equipment (PPE) on our employees.

The AI looks for hard hats, safety glasses, dosimetry badges and hearing
protection in specified locations. Before entering an area employees are
notified if they are missing any of the required PPE. Custom rules can be
set up for employees entering high hazard areas to look for radiation
monitoring equipment, as well as respiratory protection.




    
 

 

Picture placing a tool on a table and instantly identifying whether any part
of it was missing, extra, or damaged from the last time it was used. Using
multiple cameras at various angles, machine vision, and AI, the Intelligent
Foreign Material Exclusion Detection (IFMED) system aims to recognize
individual tools, perform rapid inspections of tool components and
identify any deficiencies.

FME applied to Reactor Maintenance activities is a thorough process

involving manual inspections to prevent objects such as tools and debris
from remaining inside critical systems they aren’t supposed to be in. What
ordinarily would take up to 40 minutes for a single tool could now take a
fraction of that time.

The IFMED system aims to reduce critical path time taken and dose
uptakes of personnel. Most importantly, FME events can have varying and
drastic impacts on critical systems as these tools are often used in the
nuclear reactors themselves. FME is a core aspect of maintaining nuclear
 safety at OPG.


7*46"- 3"%*"5*0/
."11*/( '03 53"*/*/(
The development of the Hololens Augmented Reality (AR) radiation=
mapping app currently in use by the Darlington Refurbishment Project for=
trainees was an effort to help better prepare workers for real in-field
experiences.

Not only can the user see the potential radiation fields in a 3D colour-
based model, they also receive haptic feedback when they get too close to=
their radiation limits. These Hololens glasses meet full safety-glass=
regulatory requirements and are attached to the hardhats via a 3D printed=
attachment. Further development for this work will include access to=
digital workplans, work instructions, drawings, manuals, etc.

As the Hololens AR equipment meets full safety requirements, they could=

be used in real-life environments rather than solely for training purposes.
% 4$)&%6-*/(
Work silos are one of the industry's challenges to overcome. Planning,
scheduling and assessing of work, engineering design, construction of
work, commissioning and turn-over can all be enhanced with better
communications between all groups through the use of VR.

X-Lab completed a minimum viable product using a real modification at

Darlington. We 3D Lidar scanned the room in which the modification was
going to be installed, modelled the design, put everything into a VR
environment, and connected this model to the Primavera schedule.

A user could see how the work would progress from shift to shift, or within
a work order or work order task. It could help the user plan, assess or
modify the work. Interferences can also be assessed ahead of time to
mitigate the chances of delays in the field due to lack of proper planning.

4D scheduling and assessment of work could help all groups create better
communication and is the future of planning and organizing complex work
projects.
     
The X-Lab has created an innovative solution for improving maintenance
on pumps and valves by manufacturing specialized gaskets.

Utilizing a 3D laser scanner, X-Lab can create a Computer Aided Design

model of a pump or valve surface, which allows Maintenance to utilize a
water jet cutter to manufacture new gaskets.

Normally, Maintenance creates gaskets by hand and can take hours to

cut a single gasket. The gasket itself is very thin and can tear easily – if it
tears, the maintainer has to start from the beginning. By 3D scanning the
part, X-Lab can custom fit the gasket, resulting in much higher accuracy
compared to traditional methods. This prevents rework and improves
reliability.

Another benefit is being able to analyze the 3D model in detail to

understand if there is any degradation on the sealing surface, which
improves overall performance of the component.
% 7*356"- &/7*30/.&/54
Using a 3D point cloud scan of the Low and Intermediate Level Waste
facility, the X-Lab morphed it into a virtual facility allowing accurate
measurements to within 1 cm.

The 3D facility allows for communication between workers located across

the province without the need to travel, greatly increasing efficiency and
providing significant cost savings.

Scans can be used to confirm plant configuration and to aid in the

modification process. In addition, new scans completed post-modification
can be compared side-by-side with originals.

This tool is simplifying plant modifications and driving efficiency at OPG's

facilities.
% *."(& 130+&$5*0/
3D Image Projection takes a QR code linked to a specific component and=
allows users to view a 3D rendering of the component to ease the=
troubleshooting and explanations of complex systems.

Initial implementation allows users to view the fuelling machine as a=

hologram on Microsoft’s Hololens or on a Surface Tablet Pro. Future=
implementation will allow up to four users all wearing Hololens units to=
view the component as it is manipulated by the users.

This innovation creates efficiency in meetings where engineers are=

required to explain complex systems as attendees are able to have a=
clearer picture of the work they're trying to complete.
It also provides a
more accurate look at the systems and components
being worked on and
improve equipment troubleshooting.
 


    
Currently, Working at Heights training involves a concrete floor within a
training facility with a line of tape on it representing where the fall hazard
is located, such as the edge of a building or scaffolding.

The number of incidents in the field where workers have not precisely
followed the steps for working at heights indicates training could be more
effective.

Using Virtual Reality (VR) to simulate realistic environments of working at

heights, results in a more effective, and engaging training program.
 
  
  
Similar to working at heights, it is also difficult to effectively train
employees for confined spaces due to the difficulty in simulating a
realistic environment.

A VR training simulator where one could enter a confined space using the
proper tools of the job, all modeled in 3D would create a realistic training
simulation for the user without putting any risk of safety on the trainee.
   

 
The Learning Centres at OPG's nuclear plants and their ability to train the
masses is constrained by limited space allocation, hours of operation,
availability of training staff, etc.

Intelligent VR simulators to test users on their ability to monitor

themselves and their possessions for radiation can be operated 24/7, and
require much less space allocation and oversight.

X-Lab has created a VR training solution for radiation monitoring, which is

currently in use by Darlington Refurbishment Project training staff.
  7*%&0 4$&/"3*04
360-degree technology combined with VR allow users to fully immerse
themselves in potentially hazardous situations from the safety and
comfort of a training setting.

Videos are currently being used to improve human performance, such as

increasing situational awareness, worker pre-job briefs, dynamic learning
activities, training, and operating experience scenarios.

Using video as a training tool helps prevent human performance errors in

the field, thus increasing overall safety of personnel and equipment.

    
  
          


     



    
  

Training using robotic tools currently takes place using robots in a full-
scale reactor unit vault mock-up, which is effective, but can result in the
mock-up being unavailable for other training for weeks at a time. This
competition for time within the vault mock-up can greatly affect training
ability and operator proficiency.

Using the same controllers being used now, but to operate a simulated
version of the robotic tools, will save the Refurbishment Project millions of
dollars and significantly increase the ability to train workers.

Simulators can be used 24/7, they are portable, and they can be used
anywhere. For those less technologically savvy operators who require
extra time to learn the skills of operating the robot, a simulator provides
them extra time to ensure they're at the same level of expertise as the
rest of the students.




   

OPG uses advanced robotics for high hazard jobs in order to protect our
workers, drive efficiencies, and to protect electrical generation.

For example, a shutter panel in a breaker cubicle became misaligned

during maintenance, and required an innovative repair solution. Due to
the high voltage of the cabinet, a bus outage would have been required to
realign the shutter, which would have cost millions of dollars of lost
generation. To avoid this, the X-Lab worked with an external vendor to
create a tool for our robot. The tool allowed operators to successfully
repair the shutter online.

The X-Lab continues to build on existing innovative solutions, such as

robots, to create more opportunities for safety and reliability.

   
    
       
  
   
  
 

  
Unmanned Aerial Vehicles (UAVs) can be used to examine and manage in
real-time the spillways (vast channels for large volumes of water) of
hydroelectric stations. A large concern surrounding spillways is the
presence of unwitting persons in the path of water. Spillways can be
flooded by large volumes of water at any moment, and the possible
presence of persons inside the spillway is an unacceptable safety hazard.

A specially designed UAV equipped with audible warning systems, optical

and thermal real-time imaging, and a bright spot-light allow for station
operators to quickly detect and warn unauthorized persons inside
spillways. The goal is for the system to be deployed on short notice, with
thermal imaging systems allowing for this monitoring to be done on short
notice, day or night.




   
 
Soon to be added to the OPG fleet is a Remotely Operated Vehicle (ROV)
complete with non-destructive testing capabilities for the inspection of
flooded draft tubes and penstocks; critical infrastructure surrounding
hydroelectric turbines. This will assist in diving inspections for locations
unsafe, difficult to access, or too small for conventional techniques. The
network design and fiber optics allows the ROV to be extremely dynamic
in what tools it uses and delivers.

All of this means that there is increased safety for personnel, better
inspection results in unfavourable conditions, and cost savings in
inspection and maintenance work.

ROV weed harvesters are also being implemented, with the goal of
reducing the time and personnel needed to clear natural debris from key
water-exposed installations. These debris can interfere with the operation
of both nuclear and hydroelectric stations and can result in costly
maintenance and possible shutdowns.




By placing a gamma measurement device on a UAV, a specially designed
system can independently operate on a predetermined flight path without
the presence of an operator. It can collect dose rate data from the reactor
face in a fraction of the time and the environment created from the data
can then be shared for work planning and training purposes.

When performing any work near the reactor face during an outage, careful
monitoring of dose uptake is essential to protect personnel. Having a
thorough understanding of dose rates with respect to face position is key
to planning work activities to reduce time spent in high dose areas.

The setup of gamma counters on the bridge not only takes time, but
exposes radiation protection personnel to the fields. Additionally, moving
the reactor bridge across the face is a painstakingly slow process. The goal
of this project is to mitigate both using the reactor face mapping UAV.
 
 
Radiation hotspots accumulate in the emergency coolant injection system
increasing ambient dose rates posing a radiation hazard that has the
potential to prevent workgroups from executing tasks.

Magnetic shielding uses metallic bands and magnetic shield. Installation is

completed in under 10 minutes, where previously lead blankets required
hours for installation. In addition, ambient dose rate decreased by 40%.

Permanently installing these metallic bands in known areas will further

decrease field exposure as workers will only receive dose when installing
and removing the magnetic shield.




4*-*$0/& 36##&3 $"5$)
$0/5"*/.&/5
The current plastic solution used to 'catch' leaks, melts under steam=
temperatures and are
difficult to install and maintain, as well as being=leaky
and costly to buy.

X-Lab has invented a better catch containment; made of platinum cured=

silicone rubber. It is radiation resistant, good up to 500°F, and is good with=
steam, D2O, T2O, H2O, and oil.

It can be assembled by one individual in less than a minute, and the=

thickness of the silicone rubber gives it the sturdiness needed to be used=
many times before it requires replacing.

It's also produced for less than half of the cost of the current method.
 
Our silicone rubber tape has been tested and proven in the most extreme
conditions and environments, and was found to withstand extremes in
temperature, pressure, voltage, moisture, corrosion and contaminants.

It creates an air-tight, water-tight seal in seconds, has an incredibly long

shelf life and resists acids, fuels, oils, radiation, solvents, liquids, steam
and ultraviolet rays.
 % 13*/5*/( 0#40-&5&
1"354
Many parts in the plant are either no longer available or difficult and
costly to obtain. In fact, the entire nuclear industry is plagued with
obsolescent parts that can no longer be purchased. 3D printing can be a
quick and cost-effective way to replace parts.

3D prints currently being used in the station include alarm panel covers,
Small Article Monitor (SAM) parts and fuse holders. The X-Lab continues
to promote innovative thinking by 3D printing obsolete parts in an effort
to improve safety, reliability, and efficiency at OPG.

   
   

  

    
    
        


      

 
  
 

  
Millions of dollars has been invested finding equivalent parts to replace
original components no longer being manufactured. A cost-effective
solution to this problem is to repair or refurbish existing obsolete
components through the electroplating of 3D printed parts.

One example we've completed over the last year was the creation of a
pump housing that was electroplated over a 3D printed model. The result
is a polished part encapsulated with durable nanometal.

There is potential to incorporate nano‐sensors within the electroplating to

perform real‐time data gathering to better predictive and preventive
maintenance programs.

Also, the ability to perform in‐situ electroplating for repair of conventional

pressure boundary components is something we are currently developing.




% */ 5)& '*&-%
"-"3. 1"/&- $07&34
The X-Lab replaced 60 sulzer control panel light covers that were in
degraded condition. These light covers were unavailable for years and
ultimately posed a safety concern for the station.

When replacement covers for the control panel couldn't be purchased

from the vendor due to obsolescence, the X-Lab took the action to use a
3D printer to recreate all 60 control panel light covers. The Engraving
Shop then fabricated equipment translucent labels for the new light
covers and the new control panel covers were successfully installed in the
sulzer Control Room.

Future implementation of 3D printed parts in the field will help improve

safety and reliability, and ensure degraded parts are replaced in a timely
fashion.
 
  
The Housekeeping and Combustible Material Safety (CMS) app gives
workers the ability to take photos of housekeeping or CMS issues and
automatically notify responsible workgroups to quickly resolve the issue.
The application allows for both online and offline use to accommodate for
areas in the station lacking cell service.

The CMS app helps employees understand their role as Nuclear

Professionals and drives a culture where employees better understand
risk. Fire poses the greatest risk to a nuclear facility and our ability to
protect the reactor core. Implementation of this app will help prevent
fires and improve OPG's already strong safety culture.

  
  
  

 


    

 

   
 
   
  
 
The Cable Program Project is an algorithm programmed to automate the
risk ranking of cables throughout the station with a Criticality Code 1 or 2.
This algorithm takes factors such as cable length, age, ambient humidity,
and load type into consideration.

This project helps improve nuclear safety by ensuring at-risk cables are
identified in a timely manner.

It also improves efficiency by automating the process, which will save us

six months of three full-time man-hours normally spent ranking cables.
The time and cost savings are undeniable.

  
 
  

           
  

   
 
 "4 -*/,&3
Asset Suite 7 (AS7) Linker is a unique X-Lab software program developed
to increase productivity and efficiency. This program automates the
manual process of searching for data and allows access to information at
the tip of your fingertips and promotes an innovative culture on a daily
basis.

Developers are continuing to improve AS7 Linker by adding new

features at the request of employees.

Through the implementation of AS7 Linker, OPG has saved nearly one
million dollars and revolutionized the way employees search for
information.


  
  


  


 

  
 
     


 


   
  
The Debris Run and Algae Mitigation App is a dynamic dashboard that
displays environment, equipment and observable conditions, and
aggregates these variables into an overall debris run risk level.

The app is used to alert workers of a potential debris run in the

immediate future. By understanding the aggregate impact, Operations
can compare the risk with how their equipment is performing and decide
whether it is appropriate to enter debris run procedures.

The app will help prevent unnecessary unit shutdowns, potentially saving
millions of dollars.
 5)& 8*3&
The Wire is a communication medium which co-ordinates the distribution
of important information to workers through electronic displays located
throughout work areas. Information currently displayed on The Wire
includes station and business priorities, unit conditions, key dates, station
and team successes, station metrics and industry operating experience.

The Wire provides streamlined communications with consistent

information displayed 24/7 to days-based and shift employees. It's an
alignment tool to increase knowledge, engage employees and drive
results across the organization.

  

   
 
    
  

   
  



  

The Photo Release app allows OPG to take promotional photos at any
time, anywhere, without needing to carry the traditional paper release
form. Prior to invention of the app, photographers had to carry hardcopy
photo release forms to be signed and then scanned back to OPG's
Graphics Department. Creation of the app removes the hardcopy
requirement and the need to scan any documents, as all information is
stored online - this is creating efficiency and saving money.

Accessible on any mobile device, OPG collects the waiver information to

ensure the release of any photo is within privacy laws. Communications is
using this application at public events and for promotional campaigns.

    
  
  
    
  
  

On any given day, any supplier is adding new carriers, customers and raw=
material suppliers. Asking all of these parties to integrate with each other=
on a continual basis is impractical. Blockchain’s distributed nature solves=
this challenge, again by completely sidestepping the problem.

Using Uranium as an example, imagine being able to securely track from=

mine, to process lab, to fuel bundle to reactor vault face. There are different
parties accountable from start to finish in this process and=integrating their
work through Blockchain would increase safety, reduce=chances of
proliferation and ensure top power output by each fuel pellet.

X-Lab is piloting a solution that demonstrates the power of blockchain in=

this capacity.
 %3: 4503"(& $0/5"*/&34
/&8 8&-%*/( 130$&44&4
The current used fuel Dry Storage Container (DSC) welding process is a
multi-day effort and weld failures often require extensive rework.

Nuclear Waste is looking at improving the welding process in two ways:

introducing new robotic welding technology such as hybrid laser arc
welding and updating the existing DSC lid weld groove design in order to
adopt this new technology. This initiative will not only reduce process time
and operating burden by half, but will also reduce welding consumables
(radiation waste) and significant repair costs.

Nuclear Waste is currently evaluating different technologies and is looking

to implement a pilot system.




   
 
    
Every ten years the vacuum building is required to undergo extensive
inspection campaigns to confirm it is fit for service. This building
constitutes the cornerstone of containment at CANDU power stations in
Ontario. Using the latest Non-Destructive Evaluation (NDE) techniques;
drones to cover the scale of the building, thermography cameras to
capture external degradation, and concrete NDE techniques, performing
detailed and thorough inspections from the outside of the vacuum
building has been proposed.

Taking this impressive structure out of service for such an extensive

campaign mandates a shutdown of the entire plant, constituting an
expensive loss of production. There’s potential to save large amounts of
outage time and reduce the total costs associated with the inspection
without compromising quality. This in turn could keep the building outage
shorter, or potentially eliminated altogether.
% -"4&3 4$"//*/( "/%
.0%&--*/(
We utilized innovative 3D laser scanning and modelling technology to
prepare the engineering design of a new personnel access platform in the
Emergency Service Water (ESW) pumphouse. Traditional means of taking
manual field measurements was difficult to accurately obtain due to the
large area and complex nature of existing equipment.

We created a huge point cloud data file of the equipment and merged a
prepared 3D CAD model of the newly engineered pump platform. We then
completed design analysis and a digital inspection of 3D data, including a
comparison of dimensions between existing field conditions and the newly
designed platform revealed various interferences. The digital design was
then revised to ensure the engineering product was ready for successful
construction.

This innovation ensures reduced field modifications, diminished schedule

holdups and minimal undetected contractor price increases - an overall
efficiency gain!
  
  

 

Non-Destructive Evaluation (NDE) techniques are at the core of inspection

and maintenance activities for both Nuclear and Renewable Generation
systems. NDE covers five main branches including Ultrasonic Testing,
Radiographic Testing, Eddy-Current Test, Liquid Penetrant Inspection, and
Magnetic Particle Inspection.

There are many sub-branches to these techniques, and the Inspection

Development and Engineering Applications (IDEAs) lab has been in the
background for over three decades developing such specialized NDE
technology for use within OPG.

One of the more recent projects was a customized Phased Array Ultrasonic
inspection which was used to inspect the High Pressure Turbine Spindles at
Pickering Nuclear. This solution was developed completely in-house for a
First of a Kind deployment. The IDEAs lab developed a solution,
implemented it successfully at Pickering Nuclear, and then won a contract to
perform the same inspection externally at Point Lepreau Generating Station
through Canadian Nuclear Partners.
1&$ 5&$)/0-0(:
Pulsed Eddy-Current (PEC) represents a revolutionary change in data
collection through insulation or coating covering a component. It allows wall
thickness measurements to be performed without removing the insulation.
Based on this feature, it is the only technology capable of performing
measurements in several locations when the station is online. There is a
continuous demand to perform online inspections.

Furthermore, based on the technology demonstrations the system can

also be used to screen for other piping condition monitoring. The main
benefit of this NDE system is to provide general wall thickness
measurement without any prerequisite tasks such as insulation removal
and scaffold building, which may be a constraint when the unit is
operating. 
   
 

Rope access isn’t a disruptive technology in the conventional sense, but the
concept of someone hanging from a rope isn’t what make this solution so
innovative; it’s all the potential places this could be used in lieu of expensive
alternatives like scaffolding.

IRI has piloted several inspection programs around the province inspecting
Renewable Generation’s fleet of penstocks using Industrial Rope Access
Trade Association (IRATA) qualified technicians. Each job has been
conducted safely, with quality and provided savings to OPG. In working at
heights situations requiring more detailed inspections, rope access has its
place in IRI’s toolkit.

Applications within our nuclear facilities are being actively explored to

determine where else this expanded expertise may be applied next.
 

   
IRI’s divers are always expanding the boundaries of what solutions can be
offered. In addition to the ROVs and recent contributions to a bubble curtain
to mitigate algae growth, they’ve proven that ultrasonic thickness
measurements can be taken remotely to help assess the condition of OPG’s
assets.

The Cygnus Dive Mk2 UT Thickness Gauge is a wrist-mounted 2.8” AMOLED

display with a transducer attached, providing a vital free hand underwater.
The unit is capable of accurate measurement with a 20 mm coating on top
of the base material. With a qualified technician on headset, the divers are
able to take readings and complete inspections on assets that were literally
inaccessible since their in-service date.
   
As OPG's infrastructure continues to age, the question of what can be done
to preventatively maintain and assess the condition of our concrete
structures is an industry in need of solutions.

IRI has variety of solutions procured exclusively to provide a swiss-army kit

of tools for the inspection of concrete; from the simpler technologies like
ground penetrating radar to the more sophisticated ultrasonic pitch-catch
methods, which use an antenna composed of an array of dry point contact
transducers emitting shear waves into concrete.

Post-processing with these tools ranges from rebar and conduit detection
to thickness measurement and detection of voids within the concrete
structure. Pairing these elements with IRI’s growing inspection expertise in
hydroelectric generating stations makes this a growing field that IRI plans to
stay at the forefront of.
    
 

The inaugural Innovation Summit hosted by IRI had two goals; empower
employees to take their creative ideas to the next level and share those
ideas across the organization. With an overwhelming attendance and over
40 ideas submitted, the next stage of this plan is to show employees their
ideas can become a reality. Several ideas progressed from the summit and
are in active development at IRI.

Ideas like having a mobile radiation shield that could be rolled into place
to protect Universal Delivery Machine workers when performing work.
These concepts start off potentially helping one group, but can have real
impact across the company.

IRI has seen engagement for innovation truly grow after the Summit, and
through these successes the hope is to continue to inspire all staff to
contribute to OPG’s future direction.